Apparatus and method for printing designs on web materials



Dec. 20, 1966 I. BERK ET AL 3,292,532

APPARATUS AND METHOD FOR PRINTING DESIGNS ON WEB MATERIALS Filed May 1, 1964 13 Sheets-Sheet 1 MV/A/G EERK CHARLES M. BEA/906W INVENTORJ 'Dec. 20, 1966 I. BERK ET AL 3,292,532

APPARATUS AND METHOD FOR PRINTING DESIGNS 0N WEB MATERIALS Filed May 1, 1964 13 Sheets-Sheet 2 INVENTORS m'w/va BER BY CHARLES M. 554/205 54 PZW/VE f aa/wa/v ATTORNEYS Dec. 20, 1966 BERK ETAL 3,292,532

APPARATUS AND METHOD FOR PRINTING DESIGNS ON WEB MATERIALS Filed May 1, 1964 13 sheets-shed 5 LPJ .4 1

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APPARATUS AND METHOD FOR PRINTING DESIGNS ON WEB MATERIALS Filed May 1, 1964 l3 Sheets-Sheet 4 FIE E INVENTORfi IR VIA/6 552K BY can: M. 554mm I. BERK ET AL Dec. 20, 1966 APPARATUS AND METHOD FOR PRINTING DESIGNS ON WEB MATERIALS 13$ Sheets-Sheet 5 Filed May 1, 1964 ATTORNEYS Dec.

I. BERK ET AL APPARATUS AND METHOD vFOR PRINTING DESIGNS ON WEB MATERIALS Filed May 1, 1964 \flos l3 Sheets-Sheet 6 INVENTORS M'v/A/z; GEEK BY Cl/AILFS M. 554105 EA); PEA/QM? eorepo/v ATToENEKS I Dec. 20, 1966 Filed May 1, 1964' I. BERK AL APPARATUS AND METHOD FOR PRINTING DESIGNS 0N WEB MATERIALS 15 Sheets-Sheet '7 00mm M. amoz/v 4); PEAK/VF gaEpa/v ATTORNEYS Dec. 20, 1966 L BERK ETAL 3,292,532

APPARATUS AND METHOD FOR PRINTING DESIGNS ON WEB MATERIALS Filed May 1, 1964 13 Sheets-Sheet 8 INVENTORS lRV/A/ SEEK C/MFL E5 M BZIEDf/V ATTORNEYS Dec. 20, 1966 I. BERK ET AL 3,292,532

APPARATUS AND METHOD FOR PRINTING DESIGNS ON WEB MATERIALS Filed May 1, 1964 16 Sheets-Sheet 9 Hh/m q 552K lNVENTORfi CAME/.55 M BEHEDEA/ I BERK ET AL Dec. 20, 1966 APPARATUS AND METHOD FOR PRINTING DESIGNS ON WEB MATERIALS M w m M M w T 6 a 4 5 w mm: n m 5 M h 67A M M w Wm. P; QQ Q m r, A N3 W t M5 Q *M Q3 0 0 E E m n 3% ii QQN QN mW N/ a 7 a c 8L N3 N3 m8 Q n3 Q? m 37 w; .S mlL SN 3% m 83 x 1 L N: l 51 Q W W Q E m\ M N Sn W w W Sn W m w m m M '00 D\ D F Aw I. BERK ET AL Dec. 20, 1966 APPARATUS AND METHOD FOR PRINTING DESIGNS ON WEB MATERIALS l3 Sheets-Sheet 11 Filed May 1, 1964 IN VENTORS mum/g [552 l. BERK ETAL 3,292,532

APPARATUS AND METHOD FOR PRINTING DESIGNS ON WEB MATERIALS Dec. 20, 1966 13 Sheets-Sheet 15 Filed May 1, 1964 fll INVENTORS //?V/A/G 554 K C'HARLEJ M5E4E0N EL); FE/IEA/E Gamma/v 47'7'0/9NEX5' lllllll'l ZREmk United States Patent 3,292,532 APPARATUS AND METHOD FOR PRINTING DE- SIGNS ON WEB MATERIALS Irving Berk, University Heights, Ohio, and Charles M. Bearden, Dalton, Ga., assignors, by mesne assignments, to J & C Carpet Company, Inc., Ellijay, Ga., 21 corporation of Georgia Filed May 1, 1%4, Ser. No. 364,336 9 Claims. (Cl. 101-115) This application is a continuation-in-part of copending application, Serial No. 258,981, filed February 18, 1963, now forfeited.

This invention relates to textile printing apparatus and particularly to a machine for applying a multicolored dye pattern to tufted carpeting. More broadly stated, this invention relates to the application of complex multicol: ored patterns or designs to web materials; to a machine for applying such complex multicolored patterns to web materials; and to a method of placing a complex multicolored pattern or design on a web material, more particularly pile carpeting.

The problem and brief rsume of the prior art Heret-ofore the printing of designs and patterns on heavy web materials such as deep pile carpeting has been effected on a commercial scale in a tedious and expensive manner. In the earlier developments of this art, a printing medium such as an engraved wood block or roll was used to apply dye from a transfer roller in the manner of a newspaper printing press. In the production of printed textile goods, a process closely analogous to this is still employed.

While satisfactory for thin goods, the printing process is not satisfactory and not fast enough for thick, heavy materials such as deep pile carpeting. Lack of color penetration, especially into the pile of carpeting, is obvious because insuificient amounts of printing medium or colorant can be carried on a transfer roll or printing block to penetrate the pile of carpeting. When a heavy application of color is attempted, smearing along the edges of the pattern results, and thus boundaries between colors in a complex multicolored design are not sharp and not strictly preserved.

From the foregoing, as a practical matter, it has only been possible to superficially apply complex patterns by printing. Where deep dyeing is to be achieved, it has been necessary to resort to techniques which are prohibitively expensive in their complexity. Yet for truly satisfactory application of color designs to carpeting, application must be made by a deep dyeing operation, i.e., by actually forcing the color to penetrate into or through the pile of the carpeting.

Subsequent developments of the art related to the immersion of the pile carpeting into open-top containers of specific design, and having thin walls. These containers were placed side-by-side. The pile was pressed into the containers so that the thin walls penetrated the pile and thus separated adjacent areas of the pile from one another in a sharp manner.

It is obvious that in this process, since there is actual immersion in liquid, drippage and surplus removal as by wringing or drying, present problems that absolutely prohibit high speed production.

Further, in the prior dip process, the-re could be no delicate blending of colors for highlight effects, overtones, and subtle color combinations.

Subsequent attempts by the art to produce deep pile color penetration have included stencils, screens, air sprays and the like. Problems with the use of sprays have arisen in adjoining or side-by-side areas of the pile.

The dye has a tendency to migrate and spread sideways when spray application is used, wi-th adjacent colors interblending or interpenetrating at the edges of adjacent color segments. Thus, boundaries have been rendered indistinct, destroying the crisp appearance which is so important in a quality product.

Such have been the results where all colors in a given design have been simultaneously applied. To overcome this difliculty, successive color applications have been tried. An obvious increase in production time has resulted from such successive color applications. Further, distortion of line is produced as each color is successively introduced and migrates through the pile.

Accordingly, a substantial advance to the art would be provided by apparatus and method for producing complex and crisp, multicolored patterns on webbing materials at high speed; and particularly adapted to the production of patterned prints in deep pile carpeting, with deep, con-trolled penetration of the color into or completely through the pile, as desired; and with highlights, overtones and subtle color blends being possible.

Therefore, a primary object of the invention is to provide a machine for simultaneously printing a plurality of difierently colored segments on carpeting which together form a multicolored geometric, floral, or pictorial pattern.

Another object is to provide -a machine for the deep dyeing of tufted, woven or pile carpeting by means of which a plurality of colored dyes may be simultaneously applied without distortion of the boundary lines between adjacent color areas.

Still another object is to provide a printed carpet, as described, with the appearance of having been fabricated from vat dyed yarns, and wherein the pattern will be maintained as the carpet surface is worn :away with use.

A further object is to provide a machine, of the type stated, for continuously moving a web of carpeting nlnder uniform tension, between unwinding and re-winding stations, past a dye-guide having a design opening cut therethrough, with a color spray :gun at each dye-guide opening, and with means for maintaining said dye-guide, color spray guns, and web, against relative movement while the color spray guns are operational.

A further important object of the invention is to provide apparatus and method for applying colored patterns to web materials on a high speed production basis, when the Web is continuously moved as the pattern is applied.

A further object is to provide apparatus for spraying complex, multicolored patterns onto pile carpeting with controlled deep penetration of the color into or through the pile, and yet maintaining sharp separation of color boundaries, and additionally providing, if desired, delicate oversprays for subtle color tone blendings and highlight effects.

A further object is to provide a method for spraying complex, multicolored patterns onto deep pile carpeting wherein the dye is actually driven or pulled, or both, into and/ or through the pile for any desired degree of penetration.

A still further object is to provide a method of deep dyeing pile carpeting that is fast, avoids overlaps, drips, bleeding and the like, and wherein the application is con-. trolled and prevented from reaching the wet stage as contrasted to prior soaking methods.

A further object is to provide a method for spraying complex patterns on carpeting involving a unique upside down color ejection wherein drips and runs are kept out of contact with the moving carpet, and product quality is thereby improved.

A further object is to provide method and apparatus for deep dyeing pile carpeting wherein a gas flow is used to set a sprayed-on dye pattern in the pile, to prevent migration of the dye from one color area to another.

Other objects of this invention will appear in the following description and appended claims, reference being had to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.

FIGURE 1 is a front elevational View of a first embodiment of the carpet printing machine that is the subject of this invention, showing a web of tufted carpeting being processed;

FIGURE 2 is a top plan view of the same;

FIGURE 3 is a fragmentary view, partly in section, taken along the line and in the direction of the arrows 3--3, of FIGURE 2;

FIGURE 4 is a fragmentary, side elevational view, similar to FIGURE 3, illustrating alternate positions of the printing box; 7

FIGURE 5 is a front elevational view of the machine taken along the line 5-5 of FIGURE 2, with portions broken away to show the relative positions of the dyeguides, carpet web, Web-supporting screen, and dye suction hoods;

FIGURE 6 is a fragmentary sectional view taken along the line and in the direction of the arrows 6-6 in FIG- URE 4;

FIGURE 7 is a vertical, sectional view on one of the dye-guides, having a four-leafed pattern, in pressed engagement with the carpet web, taken along the line and in the direction of the arrows 7-7 of FIGURE 8;

FIGURE 8 is a plan view of the dye-guide illustrated in FIGURE 7; i

FIGURE 9 is a vertical sectional view of another dyeguide having a design comprising a four-leafed pattern, with veining in each leaf, in pressed engagement with the carpet web, taken along the line and in the direction of the arrows 99 of FIGURE 10;

FIGURE 10 is a top plan view of the dye-guide illustrated in FIGURE 9;

FIGURE 11 is a top plan view of a section of the carpet web as it appears after having a multicolored composite decorative design imprinted thereon by a plurality of suitably arranged dye-guides bearing the pattern illustrated in FIGURE 8;

FIGURE 12 is a schematic layout of the pneumatic system for applying colors;

FIGURE 13 is a schematic view of the electrical control circuits for activating the pneumatic system illustrated in FIGURE 12;

FIGURE 14 is a perspective view of the printing box in its unmounted condition, showing it as it appears before the various printing components are installed therein;

FIGURE 15 is a side elevational view of a second embodiment of the invention showing vertically upward spray application as distinguished from the horizontal spray application of the first embodiment;

FIGURE 15a is an enlarged, fragmentary'side elevational view, partly in section, of the timing belt and pulley detail used in FIGURE 15;

FIGURE 16 is a front elevational view of the spray carriage, by itself, in larger detail than in FIGURE 1, for purposes of more clearly illustrating the components thereof; 8

FIGURE 17 is a fragmentary, schematic, front elevational view of the upper portion of the frame, showing the manner in which chain-carrying cams are employed to activate the carriage and then subsequently activate the spray guns;

FIGURE 17a is an elevational view taken along the line 17a-17a of FIGURE 17;

FIGURE 17b is an elevational view taken along the line 17b17b of FIGURE 17;

FIGURE 18 is a side elevational view, showing the open position of a gripping mechanism mounted on the carriage, to engage timing belts carried by the frame and thus move the carriage with the timingbelts, and thus along with the web being treated so that color application progresses at the exact rate of movement of the web through the machine;

FIGURE 19 is a view similar to FIGURE 18 showing the gripper in engaging relation with the timing belt;

FIGURE 20 is a sectional view of the gripper, as taken along line 20-20 of FIGURE 18;

FIGURE 21 is a fragmentary, top plan view of a spray mask used in the invention, with a series of illustrations thereon of various cutouts that can be made for simple as well as more complex patterns;

FIGURE 21a illustrates printed patterns produced by use of the mask of FIGURE 21;

FIGURE 22 is a fragmentary, side elevational view of the mask, showing the protective covers used therewith;

FIGURE 23 is a schematic view of an ideal spray pattern, illustrating advantageous spray gun positions relative to the mask of FIGURE 21;

FIGURE 24 is a schematic view illustrating an open position of the hood and mask frame relative to one another so that the carpeting can advance freely therebee tween during non-spray periods;

FIGURE 25 represents a closed position of parts of FIGURE 24, illustrating the manner in which spray is drawn into the carpet pile;

FIGURE 26 is a schematic view, illustrating motions of the printing apparatus, including those of the hood relative to the carpeting as the carpeting continuously advances through the machine, and also the motions of the mask relative to the carpeting;

the web being printed;

FIGURE 28 is a schematic illustration of a continuous masking system for use within the extended scope of invention;

FIGURE 28a is a fragmentary plan view illustrating color masking peninsulas as incorporated into the mask element of FIGURE 21; and

FIGURE 28b is a fragmentary plan view illustrating color masking islands that can be produced by the apparatus of FIGURE 28;

It is to be understood that the invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.

Introductory outline of the total invention Briefly, the present invention relates to the dye impregnation of a web material, such as deep pile carpeting,

by spraying a colorant material against the pile side of the carpeting and at the same time doing the following:

(a) forcing the colorant into penetrating relationship to and through the pile, with any degree of penetration desired, and under full control asto penetration;

(b) maintaining the dye application in a semi-dry con dition, thereby preventing migration;

(c) using a flow of gas to immediately set the dye, and

thereby prevent migration from one dye area to another;

line basis, or on a fixed station basis for maximum versatility.

The first embodiment: vertical web movement with horizontal spray application It is to be understood that the machine 20, illustrated in the first embodiment of FIGURES 1-l4, inclusive, is capable of printing a multicolored pattern of up to 100 different colors on a carpeting web up to 15 feet wide and of a length limited only by practical considerations of handling the web.

However, in order to simplify the explanation of the construction and operation of the machine 20, the web 27 is described as being typically 9 feet wide with a repeat pattern in four colors (red, blue, green and yellow) simultaneously imprinted thereon, to provide a continuous strip of abutting 9 foot by 12 foot rugs, as seen in FIGURE 11.

The frame The machine has a basic frame, broadly indicated by the reference numeral 21, that is fabricated from angleirons and I-beams, suitably cut and joined to provide a rigid structure for positioning and supporting the web moving and printing components, to be hereinafter identified with particularity.

The cradle and J box Again referring to FIGURE 1, at the left side and carried by the frame 21, there is seen at 22 a cradle having freely rotatable rollers 122, arranged in a curved pattern, which act to support a roll 26 of wound carpeting 27, which i pulled from the roll 26 by a pair of pressure rollers 23 and 24 driven by motor 25. The web 27, after passing between the rollers 23-24, falls into a J box 28 in loose folds 29. This condition is maintained to provide suflicient slack so that When the tail end of the web 27 is exposed at the time of run-out of the roll 26, the drive motor 25 can be stopped and a new web end attached by stitching to the tail end of the old web. The remainder of the machine can keep running and use up the slack 29 or a portion of it while a new roll is being spliced in.

The web 27 is then pulled up the long arm of the I box 28 from the slack condition 29 between pressure rollers 34 and 35, which are driven by a second motor 30 through a chain drive 36.

The printing machine proper'web support rolls From the rollers 34-35, the web 27 travels in a horizontal plane to a roller 37 over which it passes and then moves downward, in a vertical plane, through the hereinafter described printing box 70, to a roller 38 spaced downwardly of roller 37. After traveling around roller 38, the web 27 is drawn back in a horizontal plane between two pressure rollers 124 and 126, driven by motor 34 through a second chain drive 125.

The rollers 37 and 38 are mounted on shafts 43 and 44 which :are journaled crosswise of the frame 21, as seen most clearly in FIGURE 5.

The drive belts move at the speed of the web and 38.

The re-wind cradle: FIGURE 1 After passing between the rollers 124-126, the web 27 is released from tension, as at 33 in FIGURE 1, and is re-rolled, as at 58, on a re-winding cradle 32 having a plurality of interconnected rollers 123 driven by a third motor 31.

Summation Reference numeral 70 broadly indicates a printing box which is adapted to receive that portion of the web 27 traveling between the vertically spaced rollers 37 and 38, as Well as the two belts 40, as is seen most clearly in FIGURES 3, 4, and 5.

The printing box 70 comprises a rigid rectangular frame 71 open at its sides, top and bottom, and fabricated from angle-iron stock and I beams. The printing box 70 extends entirely across the width of the machine 20, and in the form shown is approximately 18 feet long. It is suspended on four spaced, vertical guide rods, or tracks, 57, through four bushings 72 located at each corner of the frame 71, as is seen most clearly in FIGURES 1, 3, and 4.

As shown in FIGURE 5, frame 71 has a belt clamping shoe 116 mounted at each end thereof and engageable with and faced toward the downwardly traveling surfaces of the belts 40. This provides vertical movement to be described later.

As shown in FIGURE 5, a rectangular dye-guide retaining frame 74 extends the length of the frame 71. A solid floor area 75 is located adjacent the dye-guide frame 74, to support spray heads 80.

Vertical movement of the printing box The printing box 70 is suspended for travel vertically of the tracks 57 by means of two cables 62, which travel over pulleys 59 and 60 and are anchored at one end to suspension hooks 73 on the printing box 70. A counterbalancing weight 61 is suspended from the other end of each cable 62, as is seen most clearly in FIGURES 1, 2 and 4.

Upward travel of the printing box 70 is limited by stops 117 positioned on each track 57.

The combined mass of the two weights 61 is such that the fully equipped printing box 70 will normally act to position itself against the track stops 117, at the upper end of its travel path.

The pusher frame of printing box 70 A rectangular pusher frame 67 extends the length of the printing box 70 and is mounted thereon through rollers 79 located at the top and bottom edges of both ends of the frame 67. The pusher frame 67 is movable on its rollers approximately 1%" toward and away from the dye-guide frame 74 by means of two pneumatic cylinders 68 mounted at each end of the printing box frame 71 and connected to the pusher frame 67 through piston rods 69 and shoes 95, as is seen most clearly in FIGURES 3, 4, and 6.

The front screen of printing box 70 A continuous rigid metal screen 78 is mounted over the front face of the pusher frame 67, as seen in FIGURE The suction hoods Five suction hoods 66, each having a square front opening measuring 36" x 36", are mounted side by side over the length of the pusher frame 67 behind the screen 78, as is seen most clearly in FIGURES 2 and 6.

The hoods 66 are connected through flexible hoses 65 to two exhaust fans 63 and 64, operating at a static pressure of 5 to 6 lbs. psi.

The piston shoes for printing box movement As shown in FIGURES 5 and 6, each piston shoe extends laterally to provide a clamping surface 95a (FIGURE 6) that is positioned behind the downwardly moving side of the belt 40 opposite the shoe 116 of the printing box frame 71. Thus, when the pneumatic cylinders 68 are energized to move the pusher frame 67 toward the dye-guide frame 74, the shoes 95 press the belt 40 against the printing box frame shoes 116, as seen in FIGURE 6, thereby clamping the printing box 70 to the moving belts which carry it downward with them at the speed of the web 27, asv long as the cylinders 68 are energized.

The control cams for printing box movement The FIGURES and 13, reference numerals 47, 48 and 49 indicate three cycling control cams mounted on a countershaft 45. Each cam is in the form of a circular disc having a circumference of 72". The countershaft 45 is driven by the roller shaft 43 through a chain drive 46 engaged with sprocket wheels on shafts 43 and 45 of relative diameters such that the cam discs will make one revolution for each 72" travel of the web 27 as it moves over the roller 37.

Each of the discs 47, 48 and 49 has cam shoes 50, 50', 51, 51, and 52, respectively, which cooperate with normally open micro-switches 53, 54 and 55, to sequentially close circuits controlled by the switches, as described in detail hereinafter, for printing box and spray head actuation.

T he dye-guides: plain version Referring to FIGURES 7 and 8, there is seen one of the dye-guides, broadly indicated by reference numeral 102, that is intended to be mounted on the dye-guide frame 74, as shown in FIGURE 5.

The dye-guide 102, illustrated, is intended to be used in the printing of the 9' x 12' carpet design shown in FIGURE 11. The pattern is broken into sections 118 and 119, measuring 36" x 36" or 18" x 18', respectively. Each dye-guide has a flat square base 103 fabricated from suitable rigid sheet material such as ply-wood, plastic, or metal. Openings 105, having the shape of each area to be dyed in a single color, are cut through the base, and sheet material collars 104 of conforming shape are fitted through each opening, as is seen most clearly in FIGURE 7. The collars 104 are open to the front and back through the base 103. The forward edges 127 of all the collars are in the same plane and are adapted to receive the web 27 in tight pressed engagement thereagainst, as shown. Each dye-guide section 102 serves as .a mask or stencil having walled openings 104 through which atomized dyes may be sprayed, as explained hereinafter.

With the machine 20, illustrated, it is possible to mount five 36" x 36" dye-guides edge to edge on the dye-guide frame 74, to imprint a web 15 feet wide. However, to create the 9 x 12 rug 120, illustrated in FIGURE 11, only three 36" x 36" dye-guides are needed. Furthermore, each dye-guide need not be 36" X 36" but may be a smaller multiple thereof, as shown by the bracketed setup indicated by reference character YZ in FIGURE 11 which has two 36" x 36" dye-guides 118 and four 18" x 18" dye-guides 119 arranged to cover an area 36" x 108". This setup is then imprinted four times under properly controlled conditions to produce the bordered 9' x 12 rug illustrated as 120.

The veined version A pattern variation; wherein undyed veining may be created withinthe area enclosed by the leaf pattern, is shown in FIGURES 9 and 10. In this form a wire grid 110 having the configuration of leaf veins is mounted flush with the forward edge 127 of each collar 104 of the dye-guide 109. When the web 27 is pressed against the dye-guide 109, as seen in FIGURE 9, the grid 110 prevents the sprayed dye from reaching the web under the grid, thereby creating a colored leaf having undyed veining in the background color of the carpet. It is of course to be understood that grids of other configuration may be substituted to provide any undyed pattern desired in the dyed area.

The spray gun heads As shown in FIGURES 1-5, inclusive, a plurality of spray gun heads are mounted in the printing box 70, one for each dye-guide opening.

These color spray heads 80 are mounted on a complex of horizontal and vertical /1" rods 76 and 77, respectively, mounted in the box frame 71 behind the dyeguide frame 74. The rods 76 and 77 are connected by means of so-called conduit clamps so that they may be positioned in any combination and at any angle needed for the proper aiming of the spray heads 80 at the dye-, guide openings.

The color spray heads 80 are of the standard type such as the Model #PAJA paint spray gun made by the De- Vilbiss Company of Toledo, Ohio. These guns have interchangeable nozzles which may be used to provide spray patterns of varied shape. There is a gun for each dye-guide opening 105, and each gun is, adjusted as to atomizing pressure, angle of approach, and distance from the opening 105, to limit its output to its particular opening. Each gun has three flexible hoses .81, 82 and 83 connected thereto, as seen in FIGURE 5, for delivery of liquid dye, atomizing air and cycling air, respectively.

The pneumatic system A schematic layout of the pneumatic system for operation of the color spray guns and accessory apparatus is shown in FIGURE 12.

As stated hereinbefore, this specification describes a four color system limited to 24 color spray heads 80 for printing the relatively simple pattern shown in FIGURE 11. It is of course to be understood that any number of, colors and intricacy of pattern may be printed with this machine, limited only by. the ingenuity of the operator.

Reference numeral indicates a trunk line carrying air under to lbs. pressure per square inch, from a compressor, not shown.

Four liquid dye reservoirs 84, 85, 86 and 87, containing red, blue, yellow and green water-dispersed dyes, respectively, are connected to trunk line 90 through a pressure regulating valve 121. Pressure in the tanks is adjusted to 15-20 lbs. p.s.i. which acts to keep the dye solution agitated. It is of course to be understood that other types of liquid dyes may be used.

Each reservoir has a distributing manifold 88 with 6 nipples 89 to which the dye hoses 81 of six guns 80 are connected.

Referring to section YZ of FIGURE 11, it will be seen that the pattern has six red leaves 112, six'blue leaves 113, six green leaves 114, and six yellow leaves 115.. Therefore, six guns are needed for each color, or twentyfour guns in all.

The line pressure in the atomizing air hoses 82 is controlled by four metering valves 91 connected'to distributing manifolds 92 having six delivery nipples 93 to which the hoses 82 are connected. Thus, the guns may be operated under closely controlled atomizing pressure. If necessary, there could be a separate pressure regulator for each hose 82.

Reference numeral 94 indicates a four-way valve controlled by an electric solenoid X. The valve 94 is connected to the two 2-way cylinders 68 which operate to Each tank has an air operated stirrer,

9 manifold 97 which is in turn connected to a valve 96, normally in a closed position, and controlled by an electric solenoid Y.

The cycling air hoses 83, of the sixteen guns used with the border pattern dye-guides 119, are connected through nipples 101 to a manifold 100 which is connected to air valve 99, normally in a closed position, and controlled by an electric solenoid Z.

The operation of the solenoids X, Y and Z is controlled by.micro-switches 53, 54 and 55 whose operating arms ride on the periphery of cam discs 47, 48 and 49, as seen in the schematic view of the electrical circuits in FIG- URE 13.

The cam discs have a circumference of 72", and, as stated hereinbefore, make one revolution each time the web 27 travels 72".

Each of the cams 47 and 48 has two shoes 50, 50' and 51, 51', respectively, positioned diametrically opposite each other so that they contact the operating arms of micro-switches 53 and 54, respectively, to close the circuits of solenoids X and Z each time the web 27 moves 36".

The cam disc 49 has one shoe 52 which contacts the operating arm of micro-switch 55 to close the circuit of solenoid Y each time the Web 27 moves 72".

The length of the shoes 50, 50; 51, 51, and 52 determines the length of time the circuits of their associated micro-switches are closed. The cam discs are normally locked together on the shaft 45, FIGURE 5, and rotate therewith as a single unit. However, in order to effect cross-timing between the circuits controlled by each cam, they may be unlocked and rotated relative to each other until the proper timing is achieved, and then re-locked. In the embodiment of the machine being described, the camming shoes of the discs are aligned so that the circuits controlled by discs 48 and 49 will not be closed until the web 27 has travelled 2" beyond the point at which the circuit controlled by disc 47 is closed.

- Operation The operation of the machine is as follows:

A web 27, in this case 9 feet wide, is drawn from a roll 26, of tufted carpeting, dyed the background color, and threaded through the machine 20, as seen in FIG- URE 1.

At the start of the printing cycle, the piston rods 69 of the pusher cylinders 68 are in a first, retracted position wherein the pusher frame 67 and screen 78 are spaced from the Web 27 with the clamping shoes 95 spaced from the belts 40. 1

The exhaust fans 63 and 64 are running, creating a suction in each of the hoods 66.

The printing box 70 is held by the counter-weights 61 in a first, or fully raised position 70a, against the track stops 117.

Liquid dye of the proper color is delivered under pressure to each spray gun 80 through the flexible hoses 81.

The hoses 82 deliver atomizing air to each gun 80 at a pressure, regulated by metering valves 91, calculated to deliver the proper spray pattern for each dye-guide opening 105.

Cycling air under 100 lbs. pressure p.s.i. is conducted to each gun through flexible hoses 83. The hoses 83 of the guns associated with dye-guides 118 receive their cycling air from manifold 97, while the hoses 83 of the guns associated with dye guides 119 receive their cycling air from manifold 100.

Since the manifold valves 96 and 99 are normally in their closed positions, there is normally no flow of air through the cycling hoses 83, therefore the dye delivery and atomizing valves of each gun are normally held closed, since they can be opened only by compressed air delivered through hoses 83.

As the Web travels downward in a vertical plane from roller 37 to roller 38 through the printing box 70, between the pusher frame screen 78 and the dye-guides mounted on frame 74, the cam discs turn in a clockwise direction until the shoe 50 of cam 47 moves the microswitch 53 to its closed position completing the circuit of solenoid X which moves the valve 94 to its second position to deliver air to the two cylinders 68, causing their piston rod '69 to travel outward to a second, extended position, wherein they press their shoes 95 against the belts 40 clamping them against the shoes 116 of the printing box frame 71, thereby locking the box 70 to the belts 40, as seen in FIGURE 6.

At the same time the pusher frame 67 is moved forward to bring its screen 78 into engagement with the carpet web 27, which it presses into firm contact with the edges 127 of the dye-guide collars 104, as seen most clearly in FIGURE 6. The printing box 70 and web 27 now move downward at the same speed in clamped engagement. The so clamped web travels until the shoe 51 of the cam 48 and the shoe 52 of cam 49 contact and close their associated micro-switches 54 and 55, respectively, to complete the circuits of solenoids Y and Z. These, in turn, open the cycling air valves 96 and 99. Cycling air passes through manifolds 97 and 100 and hoses 83 to activate all the color spray guns 80, causing atomized dye liquid to be sprayed through the dye-guide collars 104 'and on to the Web 27. At the same time the suction in the hoods 66 draws the dye spray through the Web so that there is deep penetration of the dye with little or no lateral dye travel, making for sharp outline of each dyed area. With the cam shoes at this position, the entire 9 x 3 area YZ of the web 27, shown in FIGURE 11, is printed simultaneously in red 112, blue 113, green 114, and yellow 115. When the cam shoes 51 and 52 travel beyond the micro-switches 54 and 55, the dye spray is instantly stopped. When the shoe 50 of cam 47 passes beyond the 'micro-switch 53, the solenoid X is de-activated, permitting the valve 94 to return to its first position, whereupon the piston rod 69 is retracted to its first position moving the pusher frame 67 back to its first position, spaced from the web 27, and simultaneously releasing the clamping action of the shoes 95 on the belts 40. The released printing box 70 is then free to travel upward of the tracks 57 to its first position 700-, against the stops 117.

The length of the cam shoes 50, 50. is such that the printing box 70 will travel with the web 27 a time sufficient to permit the color guns to spray the pattern on the web and then return to its starting position 70a before the web 27 has traveled 36".

As an example: At a printing rate of one complete 9' x 12' rug per minute, the web 27 moves 2 /2" per second, or 36" in 14.4 seconds. During a 2-second spray period, which is ample to lay down enough dye for each '36 section, the web will travel 5 inches. Thus, if the length of the cam shoes 50 and 50' is made such that the printing box 70 and web 27 are clamped together for 5 or 6 seconds, there will be 8 seconds left, after their release for the return of the printing box 70 to its starting position 70a before the Web 27 has traveled a full 36".

After the cam discs have turned 36" and the web has also traveled 36", the second shoe 50 of disc 47 contacts the micro-switch 53, thereby again clamping the printing box 70 to the belts 40 and pressing the web 27 against the dye-guides 118 and 119. Continued rotation of the cams brings the second shoe 51' of disc 48 into engagement with micro-switch 54 which activates the cycling valve 99 controlling the 16 spray guns associated with the "border pattern dye-guides 119. Since the cam disc 49 has no shoe spaced 36" from its shoe 52, the 8 guns controlled by cycling valve 96, which are associated with the dye-guides 118, will not be activated and no dye will be delivered at this time. The section of the design indicated by reference character Z will be printed at this time. This portion of the pattern has no leaves in its central area. At the end of this second spray cycle, the printing box 70 will again return to its first position 70a.

When the web has traveled another 36", the first printing cycle for imprinting the pattern of area YZ will be repeated, followed by the second printing cycle which imprints the pattern of area Z.

These four printing cycles will produce the 9 x 12' rug 120, illustrated in FIGURE 11. Thus, a continuous series of abutting 9 x 12 rug sections 120 will be printed along the moving web. The web travels continuously so that there is no change in the web tension. Furthermore, since the printing box 70 moves with the web 27 during each printing cycle, perfect register can be had between abutting printed sections as all colors of each section are printed simultaneously.

While a bordered 9' x 12 rug 120, having a central pattern on alternate sections, has been shown, it is to be understood that a continuous overall pattern could be printed by positioning a second shoe on the cam disc 49, diametrically opposite shoe 52, so that all the guns 80 would be activated at each 36 travel of the web.

The suction through the hoods acts to hold the web 27 firmly in a single flat plane as it is pressed against the dye-guide by the pusher screen 78, as well as pulling the dye spray deep into the web-pile.

The deep penetration of the dye gives the printed carpet the appearance of having been woven with vat dyed yarns, as well as assuring maintenance of the pattern as the carpet surface is eroded with use.

After being printed, the web 27 travels in a horizontal plane between the rollers 38 and rollers 124-126, as seen in FIGURES 1 and 2, over a bank of infra-red lamps 128 which set and dry the dye and complete the printing operation.

Tension on the moving web is then released, as at 33, and the moving web can be re-wound, as at 58, or fed to cut-01f means, not shown, for automatic division into separate 9 x 12 rugs 120.

Extended scope of the invention All types of textiles in the soft goods line, as well as carpeting, may be imprinted with this machine, whether the goods are of a Woven, felted, or other character and whether made of natural or synthetic fibers. In addition, the machine is adapted for printing on any other type of porous web.

The second embodiment: horizontal web movement with vertical spray application An utline.In order to facilitate the understanding of this embodiment of the invention, the following outline is presented to give the reader a general idea of the various major components of the machine and the logical sequence in which they are to be discussed. These major components are all shown in FIGURE 15.

(A) The web feed roll station. This comprises a roller cradle where a bulk roll of webbing such as carpeting is supported for rotation so that it can be paid out in linear fashion as it is treated in accordance with the invention. A stitcher 138 is positioned at this station for splicing on a new roll of webbing when necessary.

(B) A J box feed cont-r01 station where a slack condition is developed in the web to facilitate splicing on a new feed roll, using the stitcher positioned at the A station.

(C) A pre-dryer station.

(D) The printing machine station.

The frame. The carpet drive support rolls. The carriage drive belts. The reciprocating carriage.

The suction hood. The mask. The guns. The belt grippers. The hood actuation and the gun actuation. The carriage return. (E) The drying station. (F) The picker roll drive and roll up station.

The components in detail (A) The web feed roll stati0n.This comprises a cradle 22, as in the first embodiment of the invention. Cradle 22 has freely rotatable rollers 122, arranged in the pattern of a segment of a circle. A roll 26 of car? peting 27 is supported in cradle 22 and continuously moved therefrom in linear fashion. The rollers 122 are freely rotatable and permit the roll 26 to turn and pay out the carpeting during the processing operation.

The web or carpet 27 is moved upwardly over; a powered roll 130, positioned at the inlet end of a J box 28, the same as FIGURE 1.

132 to the sprocket of a drive motor 134, suitably supported on a frame element, not shown. The powered roll 130 is covered with a thin layer of nubby, rubber material having a high coefi'icient of friction. This'is effective to pull the carpeting along withoutthe. benefit of a top compression roll as was used in FIGURE 1 of the prior embodiment. Thus, it is evident that in this new, improved continuation-impart aspect of the invention, certain refinements have been made illustrating .a technical advancement of the art.

A stitcher is located at station A for splicing on a new bulk roll. This operation is described below..

(B) The J box feed control stati0n.-This is designated by the reference numeral 28 and is essentially the same as the unit 28 shown in FIGURE 1 of the prior embodiment of the invention.

The web 27 drops downwardly from the powered roll 130 and slides along the backside 136 of the J box 28. The web or carpeting 27 collects as a multiplicity of loose folds 29 atthe bottom of the J box 28, providing a slack condition. This condition is maintained to provide a sufficient amount of slack so that when the tail end of the roll 26 is exposed at the feed roll station A, the drive roll 130 can be stopped and a new web end attached by stitching to the tail end of the previous roll. The remainder of the machine can keep running during this interval, by using up the slack folds 29. The stitcher 138 located at station A is used for making the splice by dropping a new roll 26 into the cradle 22 and placing the exposed leading edge and the tail edge of the prior roll into the sewing machine 138 and stitching the edges together.

Thereafter, the roll is powered faster than necessary for a short interval to re-establish an appropriate amount of slack folds 29 for making a subsequent splice.

From the slack folds 29, the web 27 moves up the short front side 140 of the J box 28 to a freely rotatable guide roll 142. A pair of tension bars 144 are mounted in front of the guide roll 142. Each bar 144 is rotatably journalled at its ends on the ends of short, pivoted arms 146,carried by a frame member (not shown). Adjustq ment by clockwise movement causes the tension bars. 144

to exert an appropriate amount of drag on the carpet 27. It will be noted that clockwise turning of the rolls 144 causes the upper one of the pair to move downwardly between the other roller 144 and the guide roll 142V and thus more firmly grip the carpeting. This imposes an appropriate degree of tension on the carpet forits travel throughout the remainder of the machine, and thereby makes it possible for single rubber covered drive rolls, as will be described later, to engage the carpeting with a sufficient amount of friction to hold and move the carpeting forward at a regulated speed.

(C) The pre-dryer station.This comprises a plurality of infra-red heat lamps 148 that are mounted upon a suitable support and directed upwardly against the bottom side of the carpeting 27. The bottom side is the pile side of the carpeting. This is faced down as the carpeting is paid off the bulk roll 26 and processed through the machine. In accordance with this arrangement, the building floor proved to be a convenient means of support for the lamps 148.

The roll 130 is provided with a sprocket at one end and is connected by a chainv The broad scope of the invention is to be understood as including the lamps placed on the topside at the position 148'. Actually, positions on the lower and/or upper sides are contemplated, depending upon ambient humidity conditions. The purpose of lamps 148, 148' is to dry the web during more humid seasons of the year when processing would otherwise be somewhat hampered by too high a latent moisture content within the web. A condition of substantial dryness facilitates a good dye take deeply into the yarns of the pile of the carpeting. Therefore, the lights 148, 148' are used as necessary.

In order to move the carpeting from the pre-dry station C on into the machine, a guide roll 150 is employed. The guide roll 150 is rotatably mounted by means of pillow blocks 152 that receive the ends of shaft 154 of roll 150. The pillow blocks 152 are mounted on a suitable frame support 156. Guide roll 150 is thus mounted for free rotation and serves as a guide only and not to propel the web material through the machine. This roll is suitably rubber covered, if desired, to enable the carpet to track properly. However, this can be a naked steel roll over which the carpeting can pass freely in a sliding and roll-turning manner.

(D) The printing machine station (the frame).This comprises four upright beam elements 158, one positioned at each corner of the machine for vertical support. The beams suitably rest at their bottom ends on the floor 160.- Spanner beams 162 extend across the top of the frame and embrace and rigidify the unit. At the bottom, a spanner beam 162 also extends along the floor on each side for base support and rigidity.

The carpet drive support rolls At the upper part of the frame 164 are three carpet drive and support rolls. These are designated 166, 168, and 170. Additionally, cooperating with the lower, rear carpet drive roll 166, there is an idler roll 172. This causes the carpet to properly lap the bottom guide roll 150 and the rear carpet drive roll 166.

With an appropriate lap as indicated, single drive and guide rolls can be used when they are rubber covered. Otherwise, it has been necessary to utilize paired rolls providing a nip through which the carpeting would be fed. By the use of single rolls and appropriate laps, a more economical and fully as efficient structure is provided.

As illustrated in FIGURE 15, the rear posts 158 provide means upon which the idler roll 172 is mounted. Pillow blocks 152 are bolted to the beam 158 and extend rearwardly at each side and freely rotatably journal the shaft 171 of the roll 172. It will be noted that the carpet first passes beneath the bottom guide roll 150 at the base of the machine; and then half laps the upper guide roll 172. The carpet then passes downwardly and one-fourth laps the rear carpet drive roll 166.

A gear reduction motor unit 174,'suitably mounted on the floor 160, is used to drive all three rolls 166, 168, and 170. Power flow is first to the roll 166 and then to the other rolls. A chain 176 laps a sprocket 178 carried on the right hand end of I011 166, viewing the machine from the right hand side of FIGURE 15, which is the front for purposes of this disclosure. The right hand end of roll 166 is thus the far end when looking at the side of the machine as shown in FIGURE 15. I

From the rear roll 166, the carpet passes horizontally in a planar disposition to the front, lower drive roll 168. This roll is rubber covered and power driven to move at exactly the same speed as the rear drive roll 166. The front roll 168 is mounted in pillow blocks 152, carried by the front posts 158.

The timing belts 180 Driving power for roll 168 is derived from two timing belts 180, running between the ends of rolls 166 and 168, as shown schematically in FIGURE 15. These timing belts are horizontally disposed, but are functionally 14 generally analogous to the vertically disposed belts 40, referred to in FIGURE 1 of the first embodiment of the invention.

Typical mountings for belts 180 are shown in FIGURE 17. Thus, the shaft 182 of the forward roll 168 has a cylindrical timing belt pulley 184 secured on each end. The belt contacting faces of the pulleys 184 are provided with teeth 186, as shown in FIGURE 15a. The belts 180 are also provided with mating teeth 188. The teeth are actually ridges running across the full width of the belt and the full width of the belt contacting faces of the pulleys 186. Thus, a positive driving relationship between the belts 180 and pulleys 186, and thus between the two rollers 166 and 168 is provided. It should be noted that the pulleys 184 are of the same size, and therefore the two rolls 166 and 168 are driven at the same peripheral speed.

The roll at the upper right hand side of FIGURE 15 receives its power for rotation from the forward roll 168. This roll is also supported for rotation by means of pillow blocks 152. The purpose for power driving this roll is to produce synchronization of various operating mechanisms contained on the machine. Thus, the primary function is to actuate a carriage for spray purposes, and spray heads carried by the carriage. A secondary function of course is to aid carpet movement through the machine. A powered picker roll 190 at the upper left corner of FIGURE 15 has the primary function of drawing or pulling the carpeting 27 from the forward drive roll 168 the remainder of the way through the machine.

The synchronizing and control function performed by the upper roll 170 will not be stated at this point because it more logically follows later.

Brief review At this point it should be stated that the rolls 166 and 168 serve to orient the carpet in horizontal planar array and hold the carpet taut while moving it in a continuous forward linear manner, as to the right in FIGURE 15, designated by the arrow 192.

During this forward planar movement, a pattern is sprayed onto the carpet from the underneath side, and drawn or driven upwardly into the pile with controlled penetration, as deeply as desired. The mechanism for effecting this spray, and masking off selected areas of the carpet 27 to receive this spray is mounted on a carriage 194. The carriage 194 is mounted for movement within frame 164 of the machine and is adapted to move forwardly at the same speed as the carpeting, and release and return faster than the carpet moves forward, for recycle.

Here, a logical point arises for discussion of the carriage 194 and the manner in which it is propelled in a forward manner by connection with the timing belts to apply a spray to the carpet as it is moved along simultaneously with the carpet; and upon release of an operable connection to the timing chains, it can return for a recycle of the spraying process.

The movable carriage 194 This is shown in FIGURE 15 and also in slightly larger front elevational view, by itself, in FIGURE 16. Carriage 194 is supported for forward and backward movement by means of four rollers 198. Rails 200 carried by the machine frame 164 serve as supports for the rollers 198. The rails 200 extend from rear to front of the machine frame 164, and are connected at each end to the front and rear upright posts 158, see FIGURE 15.

As shown in each of FIGURES 15 and 16, the carriage 194 includes a frame 202 that is made up of vertical and horizontally disposed beams, suitably fastened together to form a rigid unit. Four vertical beams 204, one at each corner of the unit as shown in FIGURE 16 are comprised in the frame 202. Also, the frame 202 comprises three sets of transversely extending beam pairs 206, 208, and 210. Two of these sets are shown in FIGURE 16 and 

1. IN A WEB PRINTING MACHINE, A DYE-GUIDE HAVING A PLURALITY OF DESIGN OPENINGS CUT THERETHROUGH, MEANS FOR CONTINUOUSLY MOVING THE WEB FROM A ROLL THEREOF, AT CONSTANT SPEED AND TENSION, BETWEEN UNWINDING AND REWINDING STATIONS, PAST SAID DYE-GUIDE, A SPRAY GUN AT EACH DYE-GUIDE OPENING, OPERATIONAL TO SPRAY DYE THERETHROUGH ONTO THE WEB, MEANS FOR SUPPLYING DIFFERENTLY COLORED LIQUID DYES TO THE SPRAY GUNS, MEANS FOR INTERMITTENTLY MOVING SAID DYE-GUIDE AND SPRAY GUNS WITH THE WEB, MEANS FOR MAINTAINING THE WEB, DYE-GUIDE AND SPRAY GUNS AGAINST RELATIVE MOVEMENT WHILE THE SPRAY GUNS ARE OPERATIONAL, AND MEANS FOR OPERATING GROUPS OF SPRAY GUNS, ACCORDING TO A PREDETERMINED PLAN, SO AS TO PROVIDE REPEATED VARIATION IN THE DESIGN LAID DOWN. 